Plug-through energy monitor

ABSTRACT

A sensor for inductively measuring the current in a conductor flowing through a recess in a printed circuit board. Wire loops on the printed circuit board function as the inductive current sensor. Combined with a voltage measurement, the energy being dissipated in the conductor&#39;s load circuit can be determined and transmitted wirelessly. Control circuits can be integrated with the metering hardware to enable the remote modulation of the load&#39;s power. The inductive sensor(s) can be used to track differences between the load&#39;s supply and return currents. If a fault is detected, the circuit can be broken for safety, serving a ground fault circuit interruption (GFCI) purpose. The claimed invention can report measurements in real time, providing time series data for analyses sufficient to detect or identify an anomaly in the function and operation within a system&#39;s load or electrical power distribution network.

CROSS REFERENCE TO RELATED APPLICATIONS

The present invention claims the benefit of, priority to, andincorporates by reference, in their entirety, the follow provisionalpatent applications under 35 U.S.C. Section 119(e): 61/747,053, entitledPlug-Through Energy Sensor filed Dec. 28, 2012 and 61/921,827,Plug-Through Energy Monitor filed Dec. 30, 2013. This application is acontinuation in part of U.S. patent application Ser. No. 14/143,875,Plug-Through Energy Monitor, is incorporated by reference. Thisapplication is a continuation of U.S. patent application Ser. No.15/407,021, which is incorporated by reference.

FIELD OF INVENTION

The present invention is directed to a method, system, and apparatus foran energy sensor using a non-intrusive, magnetic-field-based currentsensor on a printed circuit board (PCB).

DISCUSSION OF THE BACKGROUND

Energy monitoring, in its known and common usage, as a unique sensingpoint for an entire unit, such as a Smart Meter, has many limitations.For example, it is very difficult to track the behavior of one piece ofequipment or appliance over time, because only the aggregate energyconsumption is recorded, making it difficult to isolate that equipment.Additionally, appliance manufacturers have very little data concerningthe way with which the users employ these appliances. This information,if available, would lead to more user-friendly and more energy efficientappliances. With the advent of the Smart Grid, real-time energyconsumption data from specific appliances becomes necessary to betterdistribute the limited resources generated by the utility companies.

There have been some attempts in the prior art at providing a plug-levelenergy monitoring solution. However, most of the products on the markettoday use some sort of resistive sensor, which breaks the current pathfrom the cord to the wall outlet. Morever, this method of energymonitoring dissipates power and makes the sensor bulky and expensive,rendering it unattractive for the users. Additionally, the energyconsumption of the sensor itself grows with the consumption of theequipment or appliance. Though this may seem insignificant in thecontext of one or two instruments, but when scaling this technology toevery outlet in every residence or office it presents a major obstaclefor adoption.

The present invention is an inexpensive and scalable solution for theplug-level energy monitoring problem. With many integration points, itis a very slim device that allows continuously measuring the energyconsumption of the equipment or appliance, without breaking the currentpath to the wall. Additional benefits include (a) no additional seriesresistance to be inserted in the circuit for current sensing, which cansave a significant amount of power for certain loads; and (b) theadvantage of incorporating the sensor into PCB allows the use ofstandard manufacturing process, reducing component count and costs.Furthermore, in certain embodiments, the distance between a conductorand sensor can be fixed by PCB design, thereby mitigating concernsrelated to calibration for the distance between conductor and sensor.

Additionally, the present invention advances the design and operation ofa Ground fault circuit interrupter (GFCI). GFCI outlets are typicallyused in kitchens and bathrooms due to the presence of water, which makesthe risk of electrocution higher. A GFCI outlet is able to sense ifelectric current is flowing through an unintended path, and then breakthe circuit to stop the flow of electric current and disable the outlet.GFCI outlets typically employ a current transformer that encompassesboth the hot and neutral wires. The signal from this current transformeris connected to a printed circuit board (PCB) with additionalelectronics. During typical operation, the electrical current flowing inthe hot and neutral wires are of the same magnitude, and in the oppositedirection. Thus, the voltage observed across the current transformerterminals is typically zero. However, if there is an alternate currentpath, e.g. through a person, the currents through the hot and neutralwires will not be the same. In this case, the current transformervoltage will be non-zero, providing a signal to an electrical ormechanical switch/relay to break the circuit. The present invention,however, permits the integration of the GFCI into the PCB of theinvention yielding improvements of the current state of the art.

BRIEF DESCRIPTION OF THE DRAWINGS

The following description, given with respect to the attached drawings,may be better understood with reference to the non-limiting examples ofthe drawings, wherein:

FIG. 1 is conceptual drawing of an exemplary PCB;

FIG. 2 is an exemplary face plate using an embodiment of the invention;

FIG. 3 is an exemplary power plug incorporating an embodiment of theinvention;

FIG. 4 is an exemplary system diagram; and

FIG. 5 is an exemplary power supply circuit.

DISCUSSION OF THE PREFERRED EMBODIMENTS

An embodiment of the invention uses a printed-circuit-board (PCB)device, which features an inductive sensor printed in between the prongsof any electrical equipment. This sensor allows a dramatic reduction inthe thickness of the measuring instrument, as compared to otherresistive-based sensors, as well as significant reduction in cost.Through magnetic coupling, the sensor observes a voltage induced at itsterminals that is proportional to the current consumed by theequipment/appliance plugged into the wall.

An associated conditioning circuit is made up of filters, amplifiers anda digital-to-analog converter which can make the data availablewirelessly, such as via Radio-Frequency messages, or through a wiredserial digital interface

The invention can be integrated into outlets, can be combined with theequipment's electrical cord, or can simply be placed as an independentcomponent between the cord and the outlet. These features make thePlug-Through Energy Monitor an ideal candidate for ubiquitous plug-levelenergy monitoring.

As shown in FIG. 1, an exemplary drawing of a PCB of the presentinvention, an embodiment of the invention may be designed with holes forvarious conductors and a current-sensor PCB coil. For a plug-throughmagnetic-field current sensor, the magnetic field must be detected inthe plane of the PCB, such as the y-z plane in FIG. 1. The magneticfield sensor in this invention consists of multiple closed loops of wirethat are sensitive to magnetic fields in the plane of the PCB. Theaforementioned wire loops are fabricated into the circuit board itselfas a series of PCB traces and layer-layer vias. This creates a number ofwire loops forming a coil (solenoid) with its main axis in the plane ofthe PCB (z-axis in FIG. 1). According to Faraday's law, a voltage isinduced in this coil due to a changing magnetic field in the z directionof the sensor PCB in FIG. 1. Therefore, this in-PCB coil is capable ofsensing magnetic fields generated by currents flowing perpendicular tothe PCB device.

For example, for a loop of infinitely thin wire, and assuming themagnetic flux density is constant in the z-direction throughout theregion of sensor loops, the magnetic field can be detected using thefollowing equation, where μ is the magnetic permeability, N is thenumber of wire loops, Aloop is the area of one loop, r is the distancebetween the conductor and wire loops, and I(t) is the current throughthe conductor.

${B(t)} = \frac{\mu\;{I(t)}}{2\;\pi\; r}$ϕ_(loop)(t) = ∫∫_(S) B(t) ⋅ dS = B(t) * A_(loop)${v_{emf}(t)} = {{- \frac{d\;\phi\;(t)}{dt}} = {{{- N}\; A_{loop}\frac{{dB}(t)}{dt}} = {\frac{\mu\; A_{loop}}{2\;\pi\; r}\frac{{dI}(t)}{dt}}}}$

Alternative methods of fabricating the magnetic-field detection includeplacing the sensor within the PCB irrespective of the location of theconductor. Furthermore, the sensitivity of the magnetic field sensor maybe improved by inter alia, adding ferromagnetic materials to increasemagnetic flux density in the PCB and thus increase the sensor's outputvoltage signal. The sensitivity of the sensor can also be increased bymaximizing the area of the wire loops relative to the current carryingconductor orientation. This can potentially be done using non-standardPCB thicknesses, or PCB fabrication processes with small vias and/or lowminimum line/space requirements.

For use in plug load sensing applications, the sensor PCB can be placedin many different locations throughout the flow of current. The sensorcan be a standalone device placed between the standard power plug andthe wall power outlet. A plug load's power plug consists of twocurrent-carrying conductors, and often a ground connection. Such a powerplug can be plugged through the previously detailed in-PCB currentsensor, and the plug load current can be measured. While power plugsvary between countries, the PCB can be redesigned to account fordifferent plug geometries. For maximum sense signal to PCB area, thesensor coil should be placed between the two current-carrying conductorsdue to the summation of magnetic fields in this region from bothcurrents.

The sensor PCB can also be built into the wall outlet faceplate shown inFIG. 2. The sensor can also be designed into the wall outlet electricalfixture itself for current sensing/energy monitoring of one or all ofthe outlets. A multi-plug power strip or surge protector could beintegrated with multiple current/energy sensors. The sensor PCB couldalso be built into a plug load's power plug itself as shown in FIG. 3.The sensor PCB could also be built into an electrical device orappliance's housing itself, elsewhere to its external power cord.

The PCB-printed inductive sensor can be built into an outlet and used toimplement this GFCI functionality with advantages over thestate-of-the-art. The PCB-printed coils can be arranged to inductivelysense the current flowing in both the hot and neutral wires separately.Thus, the two signals can be monitored to check for a current imbalanceand trigger an electrical or mechanical switch/relay to break thecircuit. This approach does not require a bulky current transformer, andthe GFCI current sensor and electronics can be integrated together on asingle PCB. Additionally, the energy being consumed by the outlet'sloads can be measured simultaneously. The electronics required for theenergy metering hardware can also be integrated on the same PCB as theGFCI electronics.

In addition to measuring the energy consumed by an electrical load, itis also beneficial to be able to control the power delivered to theload, by for example, load control. The load can be disabled completelyor modulated via a dimmer circuit. The electronics used for dimmingcould use a TRIAC or thyristor device. The load control electronics can,if desired, be integrated on the same circuit board as the load powermetering electronics. A user can control this functionality wirelesslywith a separate electronic device, for example, a cell phone, tablet, orpersonal computer. This has the benefit of being able to disableelectrical loads remotely, perhaps via a user-programmed schedule, inorder to save energy and increase building efficiency.

Analog and/or digital electronics for subsequent signal processing andcommunication can be assembled into the same PCB substrate. Thus, thePCB may include further circuitry such as a power supply, an amplifierto boost the signal coming from the sensor, and a microcontroller with aradio to send the data to either a gateway or a master sensor which thenwould relay the information to a remote location.

In order to calculate the real power being dissipated in an electricload, the voltage across the load and current flowing through it must beknown. While current sensing can be more difficult, voltage sensing canbe done in a simple yet effective way. The output of the current sensorcoil is a voltage signal that is likely very small in amplitude incomparison to an analog to digital converter's (ADC) least significantbit (LSB) size. Thus, the current sense signal may be amplified beforesampling. A low-noise operational amplifier can be connected in astandard inverting amplifier configuration to increase the magnitude ofthe signal's voltage. The addition of a capacitor in feedback introducesa low-pass frequency response for noise reduction and anti-aliasing.Multiple inverting amplifier stages can be connected in cascade toobtain very high gain before sampling the analog current sense signalwith an ADC.

A resistive voltage divider between the positive and neutral supplyvoltage conductors can be used to decrease the AC amplitude of thesignal. This is necessary to generate a signal indicative of the ACvoltage across the load that can be sampled without saturating the ADC.Alternatively, the voltage across the load could also be sensedcapacitively through the electric field between the current-carryingconductor and a separate nearby pickup/sensing conductor. Once thetime-domain waveforms for the voltage across the load and the currentflowing through it are acquired, the real power dissipated in the loadcan be calculated. The multiplication of the voltage and currentwaveforms can be done in the analog or digital domains. The output ofthis multiplication is the instantaneous power dissipation as a functionof time. This waveform can then be averaged to find the average realpower dissipated.

FIG. 4 illustrates generally the system for measurement of powerdissipation. First, the sensor detects the current, amplifies thatsignal, and voltage is determined. The output is analyzed and may betransmitted, for example to a cloud application, for further analysis.

The circuit in FIG. 5 can be used as a low-cost power supply forpowering analog and digital circuits on the PCB from a high-voltage ACvoltage source. Generally, the power supply circuit takes the power thatis supplied by the grid and converts it from an AC voltage source to aDC voltage source. The rectifier uses diodes to cut the AC voltage tothe specified range, and the capacitors dampen the transient effects.The amplification circuit amplifies the signal from the current sensorso that it can be read by the Analog-to-Digital Converter (ADC) on themicrocontroller. This power supply circuit consists of two diodes, twocapacitors, and one Zener diode. The power supply circuit rectifies anAC input voltage and generates a quasi-DC output voltage. The DC outputvoltage is adjustable and set by the reverse-bias turn-on voltage of theZener diode D3. The average output current capability is set by thevalue of capacitor C1 and the input voltage amplitude. The value ofcapacitor C2 can be chosen to meet the transient current steprequirements of subsequent load circuits. The capacitors and diodes canbe optimized for output current requirements and further optimized toreduce the footprint and thickness of the PCB while meeting system levelperformance specifications.

The PCB-based current sensor can thus be used as a standalone device ortogether with other technologies for an all-in-one energy monitoringdevice.

While certain configurations of structures have been illustrated for thepurposes of presenting the basic structures of the present invention,one of ordinary skill in the art will appreciate that other variationsare possible which would still fall within the scope of the appendedclaims.

The invention claimed is:
 1. A current monitor for measuringcyber-intrusion of a smart appliance, comprising: a. a circuit boardwith a current sensor comprised of one or more inductive pickup coils ofwire loops, the area inside the loops situated at an angle to the planeof the board; b. at least two recesses in the board from whichconductors are removably inserted; c. wherein the pickup coil is locatedbetween the recesses in the board; d. wherein the conductors arecurrent-carrying; e. wherein the currents in pairs of conductors are ofthe same magnitude but flowing in opposite directions; f. wherein thepickup coil is sensitive to a magnetic field created by the flow ofcurrent; g. wherein the pickup coil generates a signal proportional tothe currents flowing through the plane of the circuit board; h. whereinthe pickup coil generates the signal continuously; i. wherein the pickupcoil also measures current flowing in both hot and neutral wiresseparately; and j. a processor for processing energy usage data for oneor more processes running on the smart appliance for comparing theenergy usage data for baseline scenarios for a process running on thesmart appliance to detect anomalous states indicative of maliciousactivity on the smart appliance.
 2. A current monitor for detectingcyber-intrusion of a smart appliance, comprising: a. a circuit boardwith a current sensor comprised of one or more inductive pickup coils ofwire loops, the area inside the loops situated at an angle to the planeof the board; b. at least two recesses in the board from whichconductors are removably inserted; c. wherein the pickup coil is locatedbetween the recesses in the board; d. wherein the conductors arecurrent-carrying; e. wherein the pickup coil loops are printed radiallyaround each of the recesses in the board; f. wherein the currents inpairs of conductors are of the same magnitude but flowing in oppositedirections; g. wherein the pickup coil is sensitive to a magnetic fieldcreated by the flow of current; h. wherein the pickup coil generates asignal proportional to the currents flowing through the plane of thecircuit board; i. wherein the pickup coil generates the signalcontinuously; j. wherein the pickup coil also measures current flowingin both hot and neutral wires separately; and k. a processor forprocessing energy usage data for one or more processes running on thesmart appliance for comparing the energy usage data for baselinescenarios for a process running on the smart appliance to detectanomalous states indicative of malicious activity on the smartappliance.
 3. A system for detecting in real time malicious activity inthe operation of a smart appliance, comprising: a. a plug-through energymonitor, comprised of: i.) Wire loops printed on the circuit board thatfunction as an inductive current sensor to measure the current in aconductor flowing through recesses of the circuit board when theconductor is removably inserted; ii.) a voltage meter that measures thevoltage across the conductor's load circuit; iii.) analog signalconditioning circuits; iv.) analog-to-digital converter circuit; v.)processor for digital signal processing; vi.) wired or wirelessnetworking connectivity; b. a processor for processing energy usage datafor one or more processes running on the smart appliance for comparingthe energy usage data for baseline scenarios to detect anomalous statesindicative of malicious activity on the smart appliance.